Well as of today when i filled my jeep up and hit $50 mark, i decided it was time to finally tackle this beast. I hope to make this a step by step guide how to rewind your stator with better matterials, meaning that it 'should' last longer.
Initially i was going to test out several different methods to boost power output, but i need the stator now!! For this one i will stick to the basics. The remainder variations will come when i have time.
On this stator (which i got from Bumpy form the Y! forum, Thanks
)there are 30 turns per pole with about 6 ft on each pole, all in a clock wise direction. Wire gauge appears to have been 18 gauge. It was very poorly epoxied, and that seems to be the cause of the failure. removing the wire gave a quick challenge. Here are the steps.
A knife (dull but with a good point) or a chisle
needle nose pliers
pen and paper (to take notes so you dont forget)
gloves (the epoxy can be rather sharp when comming off)
a permanet marker
Toaster oven (this will be something u wont use to cook food in.
1) you will need to clean this thing very good. Use mild soap, warm water and a brush to get all the oil and debris off.
2) dry very well. you may want to put it in the toaster at 150 for 30-40 mins to dry it up.
3) mark your first pole. this should be the first one that you unwind. TAKE NOTICE HOW ITS WOUND as the wires will overlap causing issues durring this part. Pole 1 should have the end of the wire feeding over the outer part of the pole, not the inner.
4) cut off the yellow wires leaving 1/2" of wire left. same should be done with the other dohicky where all the wires connect.
5) set the toaster to 350 degrees and bake for an hour or 2. it will smolder, but not catch fire. this is to make the epoxy brittle by 'glassing' it.
6) after the heat cycle, let it cool. then take your chisle or knife and gently crack and remove as much of the epoxy as possiable from the sides of the coils. this makes unwinding eaiser. if need be take the pliers and crack it like a nut and pull some off it off.
7) take your pliers and gently pull the wire to unwind it. this may take some muscle, but be careful not to snap the wire. repeat for each coil. I found its easiest to continue with the same wire untill done (every 3rd pole)
8) wash when done.
9) rebake it at 150 30-40 mins to dry it out.
The rewind will come soon when i get parts. :P